Homogeneous amorphous marble flooring and process of making the same

Abstract

A method of manufacturing homogeneous amorphous marble flooring is disclosed. The method includes the steps of kneading a synthetic resin compound with spot color chips having various colors and primarily rolling the kneaded compound to manufacture a primarily rolled sheet, laminating the primarily rolled sheets while cutting the sheet to have a predetermined size and rotating the sheet, performing secondary rolling the laminated sheets by a low-temperature calendering to manufacture a semi-manufactured homogeneous amorphous marble flooring having wave patterns and coarse surface, pressing two pieces of the semi-manufactured homogeneous amorphous marble floorings by face-to-face pressing; and cutting the pressed semi-manufactured homogeneous amorphous marble flooring into two pieces in the horizontal direction, and then sanding and buffing the cut pieces. The manufactured novel marble flooring has a distinguishable appearance different from the convention floor.

1 . A method of manufacturing a homogeneous amorphous marble flooring, comprising the steps of: 
 kneading a synthetic resin compound with spot color chips having various colors and primarily rolling the kneaded compound to manufacture a primarily rolled sheet;    laminating the primarily rolled sheets while cutting the sheet to have a predetermined size and rotating the sheet;    performing secondary rolling the laminated sheets by a low-temperature calendering at the temperature of 60 to 100° C. to manufacture a semi-manufactured homogeneous amorphous marble flooring having wave patterns and coarse surface;    pressing two pieces of the semi-manufactured homogeneous amorphous marble floorings by face-to-face pressing; and    cutting the pressed semi-manufactured homogeneous amorphous marble flooring into two pieces in the horizontal direction, and then sanding and buffing the cut pieces.    
     
     
         2 . The method as set forth in  claim 1 , wherein the primarily rolled sheets are rotated with a vacuum suction rotation equipment, and the primarily rolled sheets are laminated by a step type continuous lamination for continuously laminating the sheets in a step shape.  
     
     
         3 . The method as set forth in  claim 1 , wherein the synthetic resin compound is added with at least one of the substituted polyglycol ether and a mixture of fatty alcohol partial esters and fatty acid esters to maintain processing temperature by 10 to 20° C. lower than conventional processing temperature.  
     
     
         4 . A method of manufacturing a homogeneous amorphous marble flooring, comprising the steps of: 
 kneading a synthetic resin compound containing 200 to 350 parts by weight of calcium carbonate, 20 to 40 parts by weight of a plasticizer, 3 to 10 parts by weight of an epoxy, 2 to 10 parts by weight of a Ba—Zn based stabilizer, 2 to 10 parts by weight of a low temperature process additive, and a variety of pigments, in 100 parts by weight of polyvinyl chloride, with spot color chips having various colors and primarily rolling the kneaded compound to manufacture a primarily rolled sheet;    laminating the primarily rolled sheets while cutting the sheet to have a predetermined size and rotating the sheet;    performing secondary rolling the laminated sheets by a low-temperature calendering at the temperature of 60 to 100° C. to manufacture a semi-manufactured homogeneous amorphous marble flooring having wave patterns and coarse surface;    pressing two pieces of the semi-manufactured homogeneous amorphous marble floorings by face-to-face pressing; and    cutting the pressed semi-manufactured homogeneous amorphous marble flooring into two pieces in the horizontal direction, and then sanding and buffing the cut pieces.